This ppt is an introduction on how we can operate maintainance of machines and installs a new machine, this guide helps for all engineering students teachers and others mainly who are engaged in MECHANICAL ENGINEERING.
Location and locating devices used in jigs and fixturesAmruta Rane
This document discusses various principles and methods of locating workpieces in fixtures. It begins by defining what is meant by location and discusses the six degrees of freedom a workpiece has. It then covers different types of locating from plane surfaces using buttons, pins, pads and adjustable supports. It also discusses locating from profiles, cylinders, and preventing issues like redundant location and jamming. A variety of locating methods and components are presented, including dowel pins, nests, and sights. The document provides guidance on selecting locating methods based on workpiece and operation requirements.
The document discusses a shaper, which is a machine tool used to produce flat surfaces on workpieces. It has a single-point cutting tool mounted on a ram that reciprocates to cut material on the forward stroke only. The workpiece is held rigidly in a vice on the machine table. The document describes the main parts of a shaper, including the base, column, ram, table, and tool head. It also classifies shapers based on the direction of ram travel and driving mechanism. Shaping operations like machining horizontal and vertical surfaces are explained.
This document provides information on numerical control (NC) and computer numerical control (CNC) machine tools. It discusses the basic components and classification of NC machines, types of numerical control systems, and part programming fundamentals for CNC machines. The document also covers topics like micromachining, wafer machining, and manual part programming for CNC machines.
The document discusses different methods of NC part programming including manual part programming, computer-assisted part programming, manual data input, NC programming using CAD/CAM, and computer automated part programming. It also provides details on punched tape formats, G-codes and M-codes used in NC part programming.
Classification of metal removal process and machines: Concept of generatrix and directrix Geometry of single point cutting tool and tool angles, tool nomenclature in ASA, ORS, NRS. Concept of orthogonal and oblique cutting, Mechanism of Chip Formation: Type of chips. Mechanics of metal cutting, interrelationships between cutting force, shear angle, strain and strain rate. Various theories of metal cutting, Thermal aspects of machining and measurement of chip tool interface temperature, Friction in metal cutting
Modern precision manufacturing demands extreme dimensional accuracy and surface finish.Such performance is very difficult to achieve manually, if not impossible, even with expert operators. In cases where it is possible, it takes much higher time due to the need for frequent dimensional measurement to prevent overcutting. It is thus obvious that automated motion control would replace manual “handwheel” control in modern manufacturing. Development of computer numerically controlled (CNC) machines has also made possible the automation of the machining processes with flexibility to handle production of small to medium batch of parts. In the 1940s when the U.S. Air Force perceived the need to manufacture complex parts for highspeed aircraft. This led to the development of computer-based automatic machine tool controls also known as the Numerical Control (NC) systems. Commercial production of NC machine tools started around the fifties and sixties around the world. Note that at this time the microprocessor has not yet been invented. Initially, the CNC technology was applied on lathes, milling machines, etc. which could perform a single type of metal cutting operation. Later, attempt was made to handle a variety of workpieces that may require several different types machining operations and to finish them in a single set-up. Thus CNC machining Centres capable of performing multiple operations were developed. To start with, CNC machining centres were developed for machining prismatic components combining operations like milling, drilling, boring and tapping. Gradually machines for manufacturing cylindrical components, called turning centers were developed.
Automatically controlling a machine tool based on a set of pre-programmed machining and movement instructions is known as numerical control, or NC.In a typical NC system the motion and machining instructions and the related numerical data, together called a part program, used to be written on a punched tape. The part program is arranged in the form of blocks of information, each related to a particular operation in a sequence
of operations needed for producing a mechanical component. The punched tape used to be read one block at a time. Each block contained, in a particular syntax, information needed for processing a particular machining instruction such as, the segment length, its cutting speed, feed, etc. These pieces of information were related to the final dimensions of the workpiece (length, width, and radii of circles) and the contour forms (linear, circular, or other) as per the drawing. Based on these dimensions, motion commands were given separately for each axis of motion. Other instructions and related machining parameters, such as cutting speed, feed rate, as well as auxiliary functions related to coolant flow, spindle speed, part clamping, are also provided in part programs depending on manufacturing specifications such as tolerance and surface finish. Punched tapes are mostly obsolete.
The document discusses the key components and features of NC and CNC machines. It explains that NC machines automate the machining process by replacing manual operator actions with programmed commands. The core elements of an NC system include the part program software, machine control unit, and machine tool. CNC machines build on NC technology with digital controllers and allow for continuous path motion control. Common CNC machine types include lathes, mills, drills, and more.
This document provides an introduction to machine elements and power transmission devices taught in the second semester of a mechanical engineering course. It discusses various machine elements like shafts, keys, couplings, bearings, clutches, and brakes. It also covers power transmission devices such as belt drives, chain drives, and gear drives. The document describes the function, types, materials, and design of these common mechanical components.
Location and locating devices used in jigs and fixturesAmruta Rane
This document discusses various principles and methods of locating workpieces in fixtures. It begins by defining what is meant by location and discusses the six degrees of freedom a workpiece has. It then covers different types of locating from plane surfaces using buttons, pins, pads and adjustable supports. It also discusses locating from profiles, cylinders, and preventing issues like redundant location and jamming. A variety of locating methods and components are presented, including dowel pins, nests, and sights. The document provides guidance on selecting locating methods based on workpiece and operation requirements.
The document discusses a shaper, which is a machine tool used to produce flat surfaces on workpieces. It has a single-point cutting tool mounted on a ram that reciprocates to cut material on the forward stroke only. The workpiece is held rigidly in a vice on the machine table. The document describes the main parts of a shaper, including the base, column, ram, table, and tool head. It also classifies shapers based on the direction of ram travel and driving mechanism. Shaping operations like machining horizontal and vertical surfaces are explained.
This document provides information on numerical control (NC) and computer numerical control (CNC) machine tools. It discusses the basic components and classification of NC machines, types of numerical control systems, and part programming fundamentals for CNC machines. The document also covers topics like micromachining, wafer machining, and manual part programming for CNC machines.
The document discusses different methods of NC part programming including manual part programming, computer-assisted part programming, manual data input, NC programming using CAD/CAM, and computer automated part programming. It also provides details on punched tape formats, G-codes and M-codes used in NC part programming.
Classification of metal removal process and machines: Concept of generatrix and directrix Geometry of single point cutting tool and tool angles, tool nomenclature in ASA, ORS, NRS. Concept of orthogonal and oblique cutting, Mechanism of Chip Formation: Type of chips. Mechanics of metal cutting, interrelationships between cutting force, shear angle, strain and strain rate. Various theories of metal cutting, Thermal aspects of machining and measurement of chip tool interface temperature, Friction in metal cutting
Modern precision manufacturing demands extreme dimensional accuracy and surface finish.Such performance is very difficult to achieve manually, if not impossible, even with expert operators. In cases where it is possible, it takes much higher time due to the need for frequent dimensional measurement to prevent overcutting. It is thus obvious that automated motion control would replace manual “handwheel” control in modern manufacturing. Development of computer numerically controlled (CNC) machines has also made possible the automation of the machining processes with flexibility to handle production of small to medium batch of parts. In the 1940s when the U.S. Air Force perceived the need to manufacture complex parts for highspeed aircraft. This led to the development of computer-based automatic machine tool controls also known as the Numerical Control (NC) systems. Commercial production of NC machine tools started around the fifties and sixties around the world. Note that at this time the microprocessor has not yet been invented. Initially, the CNC technology was applied on lathes, milling machines, etc. which could perform a single type of metal cutting operation. Later, attempt was made to handle a variety of workpieces that may require several different types machining operations and to finish them in a single set-up. Thus CNC machining Centres capable of performing multiple operations were developed. To start with, CNC machining centres were developed for machining prismatic components combining operations like milling, drilling, boring and tapping. Gradually machines for manufacturing cylindrical components, called turning centers were developed.
Automatically controlling a machine tool based on a set of pre-programmed machining and movement instructions is known as numerical control, or NC.In a typical NC system the motion and machining instructions and the related numerical data, together called a part program, used to be written on a punched tape. The part program is arranged in the form of blocks of information, each related to a particular operation in a sequence
of operations needed for producing a mechanical component. The punched tape used to be read one block at a time. Each block contained, in a particular syntax, information needed for processing a particular machining instruction such as, the segment length, its cutting speed, feed, etc. These pieces of information were related to the final dimensions of the workpiece (length, width, and radii of circles) and the contour forms (linear, circular, or other) as per the drawing. Based on these dimensions, motion commands were given separately for each axis of motion. Other instructions and related machining parameters, such as cutting speed, feed rate, as well as auxiliary functions related to coolant flow, spindle speed, part clamping, are also provided in part programs depending on manufacturing specifications such as tolerance and surface finish. Punched tapes are mostly obsolete.
The document discusses the key components and features of NC and CNC machines. It explains that NC machines automate the machining process by replacing manual operator actions with programmed commands. The core elements of an NC system include the part program software, machine control unit, and machine tool. CNC machines build on NC technology with digital controllers and allow for continuous path motion control. Common CNC machine types include lathes, mills, drills, and more.
This document provides an introduction to machine elements and power transmission devices taught in the second semester of a mechanical engineering course. It discusses various machine elements like shafts, keys, couplings, bearings, clutches, and brakes. It also covers power transmission devices such as belt drives, chain drives, and gear drives. The document describes the function, types, materials, and design of these common mechanical components.
This document discusses various assembly methods including manual, automated, and robotic assembly. It provides details on the characteristics, guidelines, types, and factors for selecting each assembly method. Manual assembly relies on human workers and is flexible but has a constant cost. Automated assembly uses machines and is best for high volumes but requires more capital. Robotic assembly falls between manual and automated in terms of volume and capital needs. The document provides pros and cons and considerations for each assembly method.
PPCE unit 3 (ME8793 – PROCESS PLANNING AND COST ESTIMATION) TAMILMECHKIT
UNIT III - INTRODUCTION TO COST ESTIMATION
Importance of costing and estimation –methods of costing-elements of cost estimation –Types of estimates – Estimating procedure- Estimation labor cost, material cost- allocation of over head charges- Calculation of depreciation cost
The document discusses different types of lathes and their components and operations. It describes the key parts of a centre lathe like the headstock, tailstock, bed, and carriage. It explains different lathe operations such as turning, facing, boring, drilling, threading and knurling. The document also discusses various methods of taper turning and thread cutting on lathes. Special attachments for centre lathes are mentioned as well to enable additional machining capabilities.
This document provides specifications for the installation of mechanical equipment. It outlines that the contractor shall install all equipment according to manufacturer's instructions and applicable codes and standards. The contractor must coordinate their work with any electrical/instrumentation installation. The contractor is responsible for unloading equipment, installing it according to drawings and specifications, ensuring proper alignment and lubrication, and performing inspections and tests prior to commissioning.
The document discusses milling fixtures and their components. Milling fixtures securely hold workpieces for milling operations. They have locating elements to precisely position workpieces and clamping elements to securely hold them against cutting forces. Key components of milling fixtures include a base, tenons to locate the fixture on the machine table, setting blocks to position cutters, and clamps or vices to hold workpieces in place. Different types of milling fixtures are used for operations like face milling or gang milling and can have mechanical, hydraulic or pneumatic clamping systems.
Chapter 3 CNC turning and machining centersRAHUL THAKER
This document discusses CNC turning and machining centers. It describes turning as a machining process using a lathe where the tool moves parallel to the workpiece axis to remove material. CNC lathes are replacing older lathes. Milling involves using rotating cutting tools to produce flat and helical surfaces. Machining centers are classified as vertical, horizontal, or universal depending on the spindle orientation. Machining centers have automatic tool changers and may have automatic workpiece positioners or pallet changers to reduce non-productive time during machining operations.
This document provides information about CNC axes and motion nomenclature. It discusses different types of CNC machine tools like gantry machines and lathes. It describes the Cartesian coordinate system used for machine coordinates, with the x, y and z axes defined using the right hand rule. The document also discusses absolute and incremental positioning systems for CNC machines.
- Drill bushes are used to guide tools like drills and reamers and are made of hardened steel.
- There are different types of bushes including press fit, removable, and special bushes. Press fit bushes provide long life while guiding tools. Removable bushes like renewable and slip bushes allow for replacement of worn bushes. Special bushes can have unique shapes to prevent tool deflection.
- Drill bushes may have collars to control hole depth or be headless. Renewable bushes are replaced through a liner bush while slip bushes provide quick changeover between operations. Threaded and plate bushes can accommodate closely spaced holes.
1. The document discusses three common cutting tools: single point cutting tool, twist drill bit cutting tool, and plain milling cutter cutting tool.
2. For each tool, it describes the main parts and provides diagrams labeling the parts. It also discusses the common angles associated with each tool type, such as back rake angle, side rake angle, and relief angles.
3. The document provides a detailed overview of the geometry and features of these basic cutting tools.
This document provides an overview of engineering drawing and its importance. It discusses that engineering drawing is used to communicate technical information through visualization, graphics theory, standards, conventions and tools. It highlights that engineering drawing is essential for all engineering disciplines as it provides the roadmaps for manufacturing products and structures. The document also explains some basics of engineering drawing like different types of lines, geometric shapes, dimensioning, projection methods, and standards and conventions used. It emphasizes that understanding the basics is important for any subject, including engineering drawing.
The document discusses limit gauging and gauge design according to Taylor's principle. It begins by defining limit gauging as using gauges to check if components lie within permissible tolerance limits rather than determining exact dimensions. It then explains Taylor's principle, which states that GO gauges check the maximum metal condition and multiple related dimensions simultaneously, while NOT GO gauges check the minimum metal condition and one dimension at a time. The document concludes by providing an example of designing GO and NOT GO plug and snap gauges according to the British system for a given shaft and hole component.
The document discusses various input and output devices used with CAD/CAM systems. It describes keyboards, mice, joysticks, light pens, scanners, touch screens, microphones, and trackballs as common input devices used to enter data and instructions into the computer. Output devices mentioned include monitors for displaying processed information, printers for printed hard copies, speakers for playing audio, and plotters for high-quality printed outputs like drawings.
The document discusses jigs and fixtures, which are tools used to precisely locate and secure workpieces during manufacturing operations like machining. It defines jigs and fixtures, describes their key elements and principles of location and clamping. It also covers different types of locating and clamping devices as well as common types of jigs like drilling jigs. Jigs are used to guide cutting tools, while fixtures only position and hold the workpiece. Together, jigs and fixtures help improve accuracy, interchangeability and efficiency of mass production.
The document discusses the Computer Aided Machine Drawing Lab Manual of R.M.K College of Engineering and Technology. It includes information about the drawing standards, welding symbols, and types of joints used in machine drawings. The objectives of the lab are also mentioned which involve studying drawing standards, limits, fits and tolerances. The document lists various assembly drawings exercises like couplings, screw jack, tailstock etc. that will be covered in the lab along with the syllabus.
Capstan and turret lathes are production lathes used to manufacture large quantities of identical parts quickly. Unlike engine lathes, they do not have tail stocks and can hold multiple tools that operate simultaneously. Capstan lathes have hexagonal turrets mounted on slides that move longitudinally, while turret lathes have stationary hexagonal turrets mounted directly on the saddle. Both types of lathes are suited for machining bars and irregular workpieces, with turret lathes able to accommodate heavier work. Common tooling includes box, flanged, and slide tool holders that mount to the turrets.
MILLING – Cutting parameters, machine time calculation
Milling operation – Plain milling, side & face milling, form milling, gang milling, end milling, face milling, T slot milling, slitting
GEAR CUTTING – Gear cutting on milling machine – dividing head and indexing method, gear hobbing, principle of operation, advantages & limitation, hobbing tech, gear shaping, gear finishing process
This document provides an overview of CNC machines. It discusses that CNC machines use a computer to convert a design into numerical codes that control machine tools to precisely shape materials. The history of CNC machines is explored, from early numerically controlled machines to modern CNCs linked directly to computers. Key parts of CNC machines are described along with their advantages in automating production, improving quality and accuracy, and manufacturing complex designs. Applications and some safety considerations are also summarized.
This document discusses different machine elements used in machines. It describes power transmitting elements like shafts, gears, pulleys and cams that transmit power from one part of a machine to another. Holding elements like nuts, bolts and pins are used to hold machine parts together. Supporting elements like bearings and brackets provide structural support. Specific power transmitting elements discussed in more detail include shafts, gears, pulleys, cams and chains. Bearings are described as machine elements that support rotating or moving parts. Different types of bearings and couplings are also summarized.
This document provides definitions and principles related to locating and clamping in jigs and fixtures design. It defines a jig as a device that holds work and locates the tool path, and a fixture as a device that locates work on a machine table. It discusses locating principles like six point location and 3-2-1 principle. It also covers various locating and clamping devices like pins, buttons, V-locators, and different types of clamps. The document aims to provide fundamental guidelines for effective design of jigs and fixtures.
This document defines pneumatic power transmission and describes its components and basic circuits. It discusses:
1) The differences between hydraulic and pneumatic systems and their common applications. Pneumatics uses compressed air and is well-suited for applications requiring quick response, low precision, and light loads.
2) The main components of pneumatic systems including compressors, cylinders, directional control valves, and other valves. Compressors produce compressed air, cylinders provide motion, and valves control airflow.
3) Basic pneumatic circuits which use symbols to represent components and show how they are connected to control airflow and component operation. Standard rules are followed when drawing pneumatic diagrams.
This document discusses different methods for manufacturing precast concrete components, including factory prefabrication, site precasting, and semi-mechanized and fully-mechanized production. It describes the main processes like forming, reinforcement, pouring, curing, and demolding, as well as auxiliary processes needed for production. Transportation of components and their erection are also outlined. The document classifies manufacturing methods as either stationary "stand" molds or moving "flow" molds in an assembly line.
This document discusses different methods for manufacturing precast concrete components, including factory prefabrication, site precasting, and semi-mechanized and fully-mechanized production. It describes the main processes like forming, reinforcement, pouring, curing, and demolding, as well as auxiliary processes. Transportation of the precast elements and their erection are also covered.
This document discusses various assembly methods including manual, automated, and robotic assembly. It provides details on the characteristics, guidelines, types, and factors for selecting each assembly method. Manual assembly relies on human workers and is flexible but has a constant cost. Automated assembly uses machines and is best for high volumes but requires more capital. Robotic assembly falls between manual and automated in terms of volume and capital needs. The document provides pros and cons and considerations for each assembly method.
PPCE unit 3 (ME8793 – PROCESS PLANNING AND COST ESTIMATION) TAMILMECHKIT
UNIT III - INTRODUCTION TO COST ESTIMATION
Importance of costing and estimation –methods of costing-elements of cost estimation –Types of estimates – Estimating procedure- Estimation labor cost, material cost- allocation of over head charges- Calculation of depreciation cost
The document discusses different types of lathes and their components and operations. It describes the key parts of a centre lathe like the headstock, tailstock, bed, and carriage. It explains different lathe operations such as turning, facing, boring, drilling, threading and knurling. The document also discusses various methods of taper turning and thread cutting on lathes. Special attachments for centre lathes are mentioned as well to enable additional machining capabilities.
This document provides specifications for the installation of mechanical equipment. It outlines that the contractor shall install all equipment according to manufacturer's instructions and applicable codes and standards. The contractor must coordinate their work with any electrical/instrumentation installation. The contractor is responsible for unloading equipment, installing it according to drawings and specifications, ensuring proper alignment and lubrication, and performing inspections and tests prior to commissioning.
The document discusses milling fixtures and their components. Milling fixtures securely hold workpieces for milling operations. They have locating elements to precisely position workpieces and clamping elements to securely hold them against cutting forces. Key components of milling fixtures include a base, tenons to locate the fixture on the machine table, setting blocks to position cutters, and clamps or vices to hold workpieces in place. Different types of milling fixtures are used for operations like face milling or gang milling and can have mechanical, hydraulic or pneumatic clamping systems.
Chapter 3 CNC turning and machining centersRAHUL THAKER
This document discusses CNC turning and machining centers. It describes turning as a machining process using a lathe where the tool moves parallel to the workpiece axis to remove material. CNC lathes are replacing older lathes. Milling involves using rotating cutting tools to produce flat and helical surfaces. Machining centers are classified as vertical, horizontal, or universal depending on the spindle orientation. Machining centers have automatic tool changers and may have automatic workpiece positioners or pallet changers to reduce non-productive time during machining operations.
This document provides information about CNC axes and motion nomenclature. It discusses different types of CNC machine tools like gantry machines and lathes. It describes the Cartesian coordinate system used for machine coordinates, with the x, y and z axes defined using the right hand rule. The document also discusses absolute and incremental positioning systems for CNC machines.
- Drill bushes are used to guide tools like drills and reamers and are made of hardened steel.
- There are different types of bushes including press fit, removable, and special bushes. Press fit bushes provide long life while guiding tools. Removable bushes like renewable and slip bushes allow for replacement of worn bushes. Special bushes can have unique shapes to prevent tool deflection.
- Drill bushes may have collars to control hole depth or be headless. Renewable bushes are replaced through a liner bush while slip bushes provide quick changeover between operations. Threaded and plate bushes can accommodate closely spaced holes.
1. The document discusses three common cutting tools: single point cutting tool, twist drill bit cutting tool, and plain milling cutter cutting tool.
2. For each tool, it describes the main parts and provides diagrams labeling the parts. It also discusses the common angles associated with each tool type, such as back rake angle, side rake angle, and relief angles.
3. The document provides a detailed overview of the geometry and features of these basic cutting tools.
This document provides an overview of engineering drawing and its importance. It discusses that engineering drawing is used to communicate technical information through visualization, graphics theory, standards, conventions and tools. It highlights that engineering drawing is essential for all engineering disciplines as it provides the roadmaps for manufacturing products and structures. The document also explains some basics of engineering drawing like different types of lines, geometric shapes, dimensioning, projection methods, and standards and conventions used. It emphasizes that understanding the basics is important for any subject, including engineering drawing.
The document discusses limit gauging and gauge design according to Taylor's principle. It begins by defining limit gauging as using gauges to check if components lie within permissible tolerance limits rather than determining exact dimensions. It then explains Taylor's principle, which states that GO gauges check the maximum metal condition and multiple related dimensions simultaneously, while NOT GO gauges check the minimum metal condition and one dimension at a time. The document concludes by providing an example of designing GO and NOT GO plug and snap gauges according to the British system for a given shaft and hole component.
The document discusses various input and output devices used with CAD/CAM systems. It describes keyboards, mice, joysticks, light pens, scanners, touch screens, microphones, and trackballs as common input devices used to enter data and instructions into the computer. Output devices mentioned include monitors for displaying processed information, printers for printed hard copies, speakers for playing audio, and plotters for high-quality printed outputs like drawings.
The document discusses jigs and fixtures, which are tools used to precisely locate and secure workpieces during manufacturing operations like machining. It defines jigs and fixtures, describes their key elements and principles of location and clamping. It also covers different types of locating and clamping devices as well as common types of jigs like drilling jigs. Jigs are used to guide cutting tools, while fixtures only position and hold the workpiece. Together, jigs and fixtures help improve accuracy, interchangeability and efficiency of mass production.
The document discusses the Computer Aided Machine Drawing Lab Manual of R.M.K College of Engineering and Technology. It includes information about the drawing standards, welding symbols, and types of joints used in machine drawings. The objectives of the lab are also mentioned which involve studying drawing standards, limits, fits and tolerances. The document lists various assembly drawings exercises like couplings, screw jack, tailstock etc. that will be covered in the lab along with the syllabus.
Capstan and turret lathes are production lathes used to manufacture large quantities of identical parts quickly. Unlike engine lathes, they do not have tail stocks and can hold multiple tools that operate simultaneously. Capstan lathes have hexagonal turrets mounted on slides that move longitudinally, while turret lathes have stationary hexagonal turrets mounted directly on the saddle. Both types of lathes are suited for machining bars and irregular workpieces, with turret lathes able to accommodate heavier work. Common tooling includes box, flanged, and slide tool holders that mount to the turrets.
MILLING – Cutting parameters, machine time calculation
Milling operation – Plain milling, side & face milling, form milling, gang milling, end milling, face milling, T slot milling, slitting
GEAR CUTTING – Gear cutting on milling machine – dividing head and indexing method, gear hobbing, principle of operation, advantages & limitation, hobbing tech, gear shaping, gear finishing process
This document provides an overview of CNC machines. It discusses that CNC machines use a computer to convert a design into numerical codes that control machine tools to precisely shape materials. The history of CNC machines is explored, from early numerically controlled machines to modern CNCs linked directly to computers. Key parts of CNC machines are described along with their advantages in automating production, improving quality and accuracy, and manufacturing complex designs. Applications and some safety considerations are also summarized.
This document discusses different machine elements used in machines. It describes power transmitting elements like shafts, gears, pulleys and cams that transmit power from one part of a machine to another. Holding elements like nuts, bolts and pins are used to hold machine parts together. Supporting elements like bearings and brackets provide structural support. Specific power transmitting elements discussed in more detail include shafts, gears, pulleys, cams and chains. Bearings are described as machine elements that support rotating or moving parts. Different types of bearings and couplings are also summarized.
This document provides definitions and principles related to locating and clamping in jigs and fixtures design. It defines a jig as a device that holds work and locates the tool path, and a fixture as a device that locates work on a machine table. It discusses locating principles like six point location and 3-2-1 principle. It also covers various locating and clamping devices like pins, buttons, V-locators, and different types of clamps. The document aims to provide fundamental guidelines for effective design of jigs and fixtures.
This document defines pneumatic power transmission and describes its components and basic circuits. It discusses:
1) The differences between hydraulic and pneumatic systems and their common applications. Pneumatics uses compressed air and is well-suited for applications requiring quick response, low precision, and light loads.
2) The main components of pneumatic systems including compressors, cylinders, directional control valves, and other valves. Compressors produce compressed air, cylinders provide motion, and valves control airflow.
3) Basic pneumatic circuits which use symbols to represent components and show how they are connected to control airflow and component operation. Standard rules are followed when drawing pneumatic diagrams.
This document discusses different methods for manufacturing precast concrete components, including factory prefabrication, site precasting, and semi-mechanized and fully-mechanized production. It describes the main processes like forming, reinforcement, pouring, curing, and demolding, as well as auxiliary processes needed for production. Transportation of components and their erection are also outlined. The document classifies manufacturing methods as either stationary "stand" molds or moving "flow" molds in an assembly line.
This document discusses different methods for manufacturing precast concrete components, including factory prefabrication, site precasting, and semi-mechanized and fully-mechanized production. It describes the main processes like forming, reinforcement, pouring, curing, and demolding, as well as auxiliary processes. Transportation of the precast elements and their erection are also covered.
Chapter 9 Machine Installation in maintenance.pptAbeyuAssefa
The document discusses machine installation and safeguarding. It covers key concepts like machine installation, foundations, anchoring, leveling, alignment and isolation. Machine installation requires proper foundations to stabilize the machine and reduce vibrations. Factors like machine size, weight and site conditions must be considered. Common installation methods include foundation anchoring and floor anchoring using j-bolts. Leveling and shaft alignment are also important installation steps. Foundation isolation further reduces vibrations. The document also discusses machine safeguarding, identifying hazardous motions and providing requirements and methods for safeguards to prevent injuries from machine operations.
Civil Works Site Construction Guidelines for Haris & Co Civil Team.pdfusamazahoor159
Thrilled to unveil the culmination of my efforts: a comprehensive set of CME guidelines meticulously tailored for on-site telecom projects. These guidelines reflect not only my expertise but also my commitment to simplifying complexities and optimizing processes in the telecom sector. Dive into the details and let's elevate our practices together!
This document summarizes a student's report on a site visit to a construction project. The student observed various construction techniques, including different types of formwork used for beams, columns, and slabs. Scaffolding types like independent scaffolding were also discussed. The project involved constructing two residential towers with amenities on a podium structure over basement parking levels. The student learned about construction processes, safety practices, and building materials and was able to see theory applied in practice during the site visit.
This document discusses the design of the Punjab Kesari Headquarters building in Delhi, India. Key points include:
- The building fuses traditional Indian architecture with a contemporary office design, using an animated facade and central atrium to optimize natural light and ventilation.
- Sustainability is a core focus, with the atrium and facade design reducing heat gain and reliance on artificial lighting.
- Digital simulations were used during design to achieve adequate natural light levels throughout the building without mechanical lighting.
- Additional simulations explored using the atrium and inlet/outlet placements to improve natural ventilation and thermal comfort on hot days.
This document discusses prefabricated concrete columns. It defines prefabrication as assembling building components in a factory and transporting them to the construction site. Precast concrete columns can be single or double-story height and are made in modular designs to accommodate different heights. Columns have widths of 300mm, 450mm, or 600mm and can be rectangular or circular. Connection methods between the column and foundation include cast-in base plates, dowel tubes, or projections. The manufacturing process for precast concrete components involves 10 main steps including installing molds and reinforcement, pouring and vibrating concrete, curing, and removing molds.
Box Pushing Technique was adopted to form abutments and construction of RCC road slab in between the abutments to construct the Underpass below running railway tracks.
This document provides details about the construction of a residential building with 7 flats in Nagpur, India. It describes the foundation layout including spread footings and reinforcement. Preparations for the slab pour are outlined, including leveling, formwork, reinforcement, and calculating the concrete volume. Activities after casting like curing and starter columns are also summarized. The conclusion reflects on how the training helped provide practical experience in areas like planning, execution, and concrete volume calculations.
Draglines are large excavation machines used to remove material from pits and deposit it elsewhere. They operate by casting a bucket attached to cables away from the machine to excavate, then pulling the loaded bucket back and swinging it to dump the material. The main types are crawler-mounted, wheel-mounted, and truck-mounted. Production depends on factors like bucket size, boom length, depth cut, swing angle, and material. Safety precautions when using draglines include keeping people away from the swing area and not swinging loads over equipment.
The document discusses prefabrication principles including definitions, needs, advantages, disadvantages, requirements for planning prefabricated plants, and modular coordination concepts. Prefabrication involves assembling building components off-site and transporting them for on-site construction. It offers benefits like reduced costs, time, and waste but requires careful handling and transportation. Planning prefabricated plants involves selecting types, locations, production processes, and optimized layouts. Modular coordination standardizes dimensions using basic modules to facilitate prefabrication and industrialization.
This document discusses formwork, which is a mould used to contain and shape concrete until it hardens. Formwork is commonly made from timber or steel. It must be strong enough to support the weight of wet concrete and other loads without excessive deflection. Proper formwork design considers containment, strength, water tightness, accuracy, ease of handling, finish quality, and cost. The document describes formwork requirements and objectives, as well as details for common structural elements like walls, columns, beams, slabs, stairs, and removal procedures.
This document provides an overview of mechanized construction and various types of construction equipment. It discusses the phases and benefits of mechanization for construction projects. Various earthmoving equipment are described in detail, including excavators, loaders, graders, backhoes, bulldozers, trenchers, scrapers, shovels, and draglines. Their uses, applications, and selection criteria for different project needs are explained. The document serves as a reference for understanding fundamental mechanical concepts and commonly used equipment in mechanized construction.
This document provides information about slip formwork construction for chimneys. It begins with an introduction to slip formwork and its use for building tall structures like silos and grain elevators in the early 20th century. It then discusses the process of slip forming involving a moving form that is jacked upwards as concrete is poured in. The document outlines the key steps, components, structural concerns and provides an example case study of slip forming used at the Kudankulam Nuclear Power Plant in India.
PMT80 Foundation Design & Installation & Commissioning & Safety.pdfssuseref23d3
This chapter discusses the installation and operation of a passenger and material hoist. It includes topics on preparing the site before installation, safety during erection, locating the hoist, constructing the foundation, erecting the mast sections, installing wall ties, and commissioning the completed hoist. The foundation must be able to support the static and dynamic loads of the hoist. The mast sections are erected one by one and secured with bolts. Wall ties are attached at predetermined points to transfer loads to the building structure. Electrical, limit switch, and other component installations are also covered. Proper procedures and safety measures must be followed during installation.
Selection of Roof Casting Formwork Systems for the Bird Island Project: Case ...Muhammad Umar
Selection of Roof Casting Formwork Systems for the Bird
Island Project: Case Study.
The paper illustrates the complexities involved in the selection and deployment of a formwork system through a study of
the concrete formwork selection on the Bird Island Flats Tunnel project. This $290 million project was a part of the Central Artery/Tunnel
project in Boston, Massachusetts. Because the conventional shoring methods could not produce the output needed to meet the project
schedule and budget, the contractor solicited proposals from formwork manufacturers and chose the system from CONESCO Industries.
Software Engineering and Project Management - Introduction, Modeling Concepts...Prakhyath Rai
Introduction, Modeling Concepts and Class Modeling: What is Object orientation? What is OO development? OO Themes; Evidence for usefulness of OO development; OO modeling history. Modeling
as Design technique: Modeling, abstraction, The Three models. Class Modeling: Object and Class Concept, Link and associations concepts, Generalization and Inheritance, A sample class model, Navigation of class models, and UML diagrams
Building the Analysis Models: Requirement Analysis, Analysis Model Approaches, Data modeling Concepts, Object Oriented Analysis, Scenario-Based Modeling, Flow-Oriented Modeling, class Based Modeling, Creating a Behavioral Model.
Redefining brain tumor segmentation: a cutting-edge convolutional neural netw...IJECEIAES
Medical image analysis has witnessed significant advancements with deep learning techniques. In the domain of brain tumor segmentation, the ability to
precisely delineate tumor boundaries from magnetic resonance imaging (MRI)
scans holds profound implications for diagnosis. This study presents an ensemble convolutional neural network (CNN) with transfer learning, integrating
the state-of-the-art Deeplabv3+ architecture with the ResNet18 backbone. The
model is rigorously trained and evaluated, exhibiting remarkable performance
metrics, including an impressive global accuracy of 99.286%, a high-class accuracy of 82.191%, a mean intersection over union (IoU) of 79.900%, a weighted
IoU of 98.620%, and a Boundary F1 (BF) score of 83.303%. Notably, a detailed comparative analysis with existing methods showcases the superiority of
our proposed model. These findings underscore the model’s competence in precise brain tumor localization, underscoring its potential to revolutionize medical
image analysis and enhance healthcare outcomes. This research paves the way
for future exploration and optimization of advanced CNN models in medical
imaging, emphasizing addressing false positives and resource efficiency.
Applications of artificial Intelligence in Mechanical Engineering.pdfAtif Razi
Historically, mechanical engineering has relied heavily on human expertise and empirical methods to solve complex problems. With the introduction of computer-aided design (CAD) and finite element analysis (FEA), the field took its first steps towards digitization. These tools allowed engineers to simulate and analyze mechanical systems with greater accuracy and efficiency. However, the sheer volume of data generated by modern engineering systems and the increasing complexity of these systems have necessitated more advanced analytical tools, paving the way for AI.
AI offers the capability to process vast amounts of data, identify patterns, and make predictions with a level of speed and accuracy unattainable by traditional methods. This has profound implications for mechanical engineering, enabling more efficient design processes, predictive maintenance strategies, and optimized manufacturing operations. AI-driven tools can learn from historical data, adapt to new information, and continuously improve their performance, making them invaluable in tackling the multifaceted challenges of modern mechanical engineering.
Introduction- e - waste – definition - sources of e-waste– hazardous substances in e-waste - effects of e-waste on environment and human health- need for e-waste management– e-waste handling rules - waste minimization techniques for managing e-waste – recycling of e-waste - disposal treatment methods of e- waste – mechanism of extraction of precious metal from leaching solution-global Scenario of E-waste – E-waste in India- case studies.
Batteries -Introduction – Types of Batteries – discharging and charging of battery - characteristics of battery –battery rating- various tests on battery- – Primary battery: silver button cell- Secondary battery :Ni-Cd battery-modern battery: lithium ion battery-maintenance of batteries-choices of batteries for electric vehicle applications.
Fuel Cells: Introduction- importance and classification of fuel cells - description, principle, components, applications of fuel cells: H2-O2 fuel cell, alkaline fuel cell, molten carbonate fuel cell and direct methanol fuel cells.
Comparative analysis between traditional aquaponics and reconstructed aquapon...bijceesjournal
The aquaponic system of planting is a method that does not require soil usage. It is a method that only needs water, fish, lava rocks (a substitute for soil), and plants. Aquaponic systems are sustainable and environmentally friendly. Its use not only helps to plant in small spaces but also helps reduce artificial chemical use and minimizes excess water use, as aquaponics consumes 90% less water than soil-based gardening. The study applied a descriptive and experimental design to assess and compare conventional and reconstructed aquaponic methods for reproducing tomatoes. The researchers created an observation checklist to determine the significant factors of the study. The study aims to determine the significant difference between traditional aquaponics and reconstructed aquaponics systems propagating tomatoes in terms of height, weight, girth, and number of fruits. The reconstructed aquaponics system’s higher growth yield results in a much more nourished crop than the traditional aquaponics system. It is superior in its number of fruits, height, weight, and girth measurement. Moreover, the reconstructed aquaponics system is proven to eliminate all the hindrances present in the traditional aquaponics system, which are overcrowding of fish, algae growth, pest problems, contaminated water, and dead fish.
Null Bangalore | Pentesters Approach to AWS IAMDivyanshu
#Abstract:
- Learn more about the real-world methods for auditing AWS IAM (Identity and Access Management) as a pentester. So let us proceed with a brief discussion of IAM as well as some typical misconfigurations and their potential exploits in order to reinforce the understanding of IAM security best practices.
- Gain actionable insights into AWS IAM policies and roles, using hands on approach.
#Prerequisites:
- Basic understanding of AWS services and architecture
- Familiarity with cloud security concepts
- Experience using the AWS Management Console or AWS CLI.
- For hands on lab create account on [killercoda.com](https://killercoda.com/cloudsecurity-scenario/)
# Scenario Covered:
- Basics of IAM in AWS
- Implementing IAM Policies with Least Privilege to Manage S3 Bucket
- Objective: Create an S3 bucket with least privilege IAM policy and validate access.
- Steps:
- Create S3 bucket.
- Attach least privilege policy to IAM user.
- Validate access.
- Exploiting IAM PassRole Misconfiguration
-Allows a user to pass a specific IAM role to an AWS service (ec2), typically used for service access delegation. Then exploit PassRole Misconfiguration granting unauthorized access to sensitive resources.
- Objective: Demonstrate how a PassRole misconfiguration can grant unauthorized access.
- Steps:
- Allow user to pass IAM role to EC2.
- Exploit misconfiguration for unauthorized access.
- Access sensitive resources.
- Exploiting IAM AssumeRole Misconfiguration with Overly Permissive Role
- An overly permissive IAM role configuration can lead to privilege escalation by creating a role with administrative privileges and allow a user to assume this role.
- Objective: Show how overly permissive IAM roles can lead to privilege escalation.
- Steps:
- Create role with administrative privileges.
- Allow user to assume the role.
- Perform administrative actions.
- Differentiation between PassRole vs AssumeRole
Try at [killercoda.com](https://killercoda.com/cloudsecurity-scenario/)
artificial intelligence and data science contents.pptxGauravCar
What is artificial intelligence? Artificial intelligence is the ability of a computer or computer-controlled robot to perform tasks that are commonly associated with the intellectual processes characteristic of humans, such as the ability to reason.
› ...
Artificial intelligence (AI) | Definitio
2. • What is the place of Maintenance
Professionals in Industry?
Maintenance Planner
Sales Engineer
Maintenance Engineer
Technique Manager
3. • Which industries require the service of
maintenance professionals?
• All manufacturing industries:
Metal industries
Plastic factories
Automotive industries
Cement factories
Lather and Lather Products
Textile and Garment Factories
Breweries
Soft drink factories
Alcohol and liquor factories
Food processing industries
Construction industries, etc.
• Service industries
Hotels and Resorts
4. • What is Maintenance?
• Maintenance can be considered as a
combination of activities directed towards
preservation and restoration of the performance
of a facility, machine or equipment.
• Which comprises:
• service
• repair,
• replace, and
• modify components of a machine/equipment.
1. INTRODUCTION
5. • The main purposes of maintenance:
to eliminate system failures and hazards.
to ensure that equipment continues to work
within the design tolerances and
specifications.
to ensure the defined functions and standards
of operations of the plant are maintained, and
to ensure equipment are capable of being
performed for the required period.
1. INTRO. Cont.
6. Inadequate or lack of effective and efficient
maintenance system especially in a manufacturing
enterprise gives rise to several undesirable
consequences. These consequences include:
(i) Excessive machine breakdown
(ii) Frequent emergency maintenance work
(iii) Shortened life-span of the facility
(iv) Poor use of maintenance staff
(v) Loss in production output
(vi) Inability to meet delivery dates
(vii) Excessive overtime
1. INTRO. Cont.
Effect of Poor Maintenance
7. • The level of maintenance required at the
equipment operation stage is affected by
factors at other stages through which the
equipment passes. Theses are:
1. Design stage:
2. Installation stage:
3. Commissioning stage:
4. Operational stage:
1. INTRO. Cont.
8. 1. Design stage:
Reliability and maintainability are the important factors
which should be considered properly in relation to
performance of equipment, capital and running costs.
2. Installation stage:
Maintainability is an important factor to be considered
during the installation, for it is here that maintenance
problems become clear.
3. Commissioning stage:
This is a stage of technical performance testing and also
a stage of where primary design faults are located and
designed out.
4. Operational stage:
The operational stage is a stage of learning where
maintenance plays an important role.
1. INTRO. Cont.
9. 2. Basics of Machine Installation
2.1. General Procedure of Machine Installation
Installation procedure of a machine involves a
series of activities like:
a) Location and layout;
b) Positioning of machines;
c) Foundation;
d) Leveling and alignment;
e) Grouting;
f) Fitting of other parts, accessories, piping etc.;
g) Final leveling and test runs
10. a) Location and Layout
• The location of a machine depends on its purpose of
installation, definite types and sizes and other special
requirements, if any.
• For example, a centrifugal pump location should be as
close to the source of water as possible when suction lift is
present, or for a compressor location may be selected near
the particular shop where maximum air will be consumed
and at the same time a clear intake air will be available.
• Moreover the location plan should permit to have required
wide space all-around for continuing the erection work and
should facilitate regular inspection, repairing, etc.
• The location should also be finalized in such a fashion that
it will not disturb or obstruct the operation and
maintenance work of other nearby machines.
11. a) Location and Layout Cont.
• Once the location is finalized, the work of laying
out the foundation plan is to be undertaken.
• Laying out means marking of the foundation plan.
It may be done with the help of chalk on a
concrete floor and by a string with a number of
pegs.
• The general procedure is to indicate the outlines as
per specification of the machine.
• The axis lines are to be drawn both longitudinally
and crosswise to locate the center of foundation.
• Excavation of soil may be started only when the
layout is completed as per the requirement.
12. b) Positioning of Machines
• Positioning of the machine at the location is an important
job, which deserves care, skill an efficient teamwork.
• An equipment may have the weight of a few tons. But it is
to be loaded or unloaded, to be moved vertically or
horizontally to bring it at the site and to place it on the
foundation as well.
• Different types of lifting devices like pulley blocks, chain-
hoists, overhead cranes etc. may be used as per the
availability and requirement.
• When the load is light, rope pulley blocks are widely used
and chain pulley blocks may be useful, but for a very
heavy load, electric cranes are generally employed.
• However, the slinging should be done with much care to
avoid any impact shock, to avoid formation of any
scratches and breakages, etc.
13. b) Positioning of Machines Cont.
• For a machine of about 2 tones, hemp rope or
Manila rope of diameter about 4 to 5 cm may be
used instead of chains, wooden blocks and felts
should be interposed between rope and the
machine, to avoid damage to the finishing.
• Care must be taken to sling the machine upright
with weight distributed evenly. Thus, the efficient
fixing and passing of ropes or ‘chains’ through the
machine structure deserves skill and experience.
• Two typical slinging diagram (Fig. 1: a & b) are
given for a lathe and a vertical milling machine
respectively to explain the complicacies of
slinging.
15. c) Foundation
• The shapes and sizes of the foundation differ according
to the type and size of the machines.
• They are also dependent on the property of the subsoil
and the dynamic loads of the machine during operation.
• If the weight of the installed machine is not too much
or if the dynamic loads are insignificant, the size of the
foundation may be finalized on the basis of design
considerations.
• But when the dynamic loads predominant, the
foundation should also serve the purpose to protect the
machine from external vibration and to lower down the
frequency of natural vibration by increasing its total
mass.
16. c) Foundation Cont.
Dynamic and Static Loads
•For example, for a rotary machine, the following empirical
formula may be used to find out the equivalent static load
(Pstatic):
Pstatic = G/g.e. (Πn/30)2
kdynamic
Where G = Weight of rotating masses.
g = acceleration due to gravity.
e = eccentricity of rotating masses.
n = Speed of the work-piece.
and ‘kdynamic ‘ is the dynamic co-efficient generally taken as
1.5 to 2.
•For a reciprocating machine, the general practice is to take
the equivalent static force as five or six times the value of
cutting force.
17. c) Foundation Cont.
• The dimensions of the foundation block may be determined, primarily
finding out the weight of the foundation (WF) with the following
empirical formula:
• WF = KF.WM
• Where, KF is a factor, commonly taken as 2.3 for the machine tools
with dynamic load and WM is the weight of the ‘machine tool’.
• The height of the foundation = Weight of the foundation (WF) / Area
of the base of foundation X Specific weight of material.
• Of course, the height, so calculated should be sufficient enough to
accommodate the foundation bolts etc.
• The width and length of the foundation can be suitably calculated
considering the foundation drawing, its height and weight.
• Normally, it is recommended that as far as possible, the foundation
should be so dimensioned that the resultant force due to the mass of
the machine and the mass of the foundation passes through the center
of gravity of the basic contact area, especially for a rotary machine.
18. c) Foundation Cont.
Other Design Criteria for Foundation
•Besides the dimensions, as stated above, some other
criteria are also considered for suitable foundation work.
i. Ground Condition
•The nature of soil is obviously a vital criterion. For a hard
soil or for a normal soil, the construction of a concrete bed
does not entangle too many complicacies. It is rather most
straightforward to consider the foundation plan supplied by
the manufacturer.
•But, for soft and loose soil, a large surface area with
proper depth is needed for the foundation of a machine.
19. • The problems encountered due to vibration may force to
construct a concrete raft (1) on piles (2), as shown in Figure
2.
c) Foundation Cont.
Figure 2: (a) Raft on Piles; (b) Bondage of Raft with Pile.
• The main structure of the machine is erected on the piles.
The piles should have a stable and rigid bond with the raft as
shown separately in the Figure 2b.
• The bond may be a reinforced concrete having a steel-rod
within it.
• For water-logged soils also, mostly the pile driven raft
construction is the means to avoid problems due to
subsidence of soil.
20. Vibration Consideration
•To avoid transmission of vibration to adjoining parts of buildings or
other foundations, it is necessary to provide a suitable isolation
between the equipment foundation and the joining structure.
•Usually a gap is maintained all around the foundation (like a
trench), and is filled by sand to avoid such transmission of vibration.
•Any vibration isolating material, other than sand, such as rubber,
lead sheet, felt etc. may also be used.
•As a rule, the equipment foundation shall not be allowed to serve as
support for other structures or for machineries not related to the
particular equipment.
•The impact type machines, like stamping press, drop and forging
hammer, need special care during foundation. The depth of the
foundation becomes very large to make the foundation heavy.
c) Foundation Cont.
21. c) Foundation Cont.
• Figure 3a shows a sand-filled trench all-around the concrete
foundation block. Such a foundation design reduces vibration
transmission.
• Figure 3b shows that the foundation block is placed on some
inserts, below which the concrete (reinforced concrete) base is
there.
• The air gap is maintained all-around and at the same time there is
an elastic support (to provide cushioning effect) in between the
foundation block and the equipment.
• Such a design avoids vibration transmission and absorbs shock as
well. The soft inserts may be cork or timber sleepers etc.
Figure 3: (a) Sand-filled
trench around
foundation; (b) Soft
insert below foundation
block.
22. c) Foundation Cont.
Foundation bolts
•To install the machineries, foundation bolts will be specified and
supplied by the manufacturers. Some of the foundation bolts become
rigid on pouring concrete and some may be removable and adjustable
bolts.
•A few type of foundation bolts, very commonly used, are discussed
below.
Eye foundation bolts
•They are generally made of mild steel or wrought-iron and can be
readily forged according to the size. They are very much suitable to
use for fastening the lids to tanks etc. (Fig. 4).
Figure 4: Eye Foundation Bolt.
23. c) Foundation Cont.
Rag bolt
•Rag bolts (Fig. 5a) are rectangular in cross-section but the width of
the rectangle increases gradually. They are having an indented or
grooved edge.
•After suspension of the bolts, the gap around them may be filled-up
with molten lead.
•Such bolts cannot be removed easily after grouting.
Lewis bolt
•Such bolts can be removed easily, as a tapered key (1) is fitted
through the side of the bolts to make it rigid.
•It may be noted that the key is fitted on the straight face of the bolt
body. (Fig. 5b)
Figure 5: (a) Rag
bolt; (b) Lewis
bolt.
24. c) Foundation Cont.
Cotter bolt
•To install heavy-machines, ‘cottered bolts’ are commonly used (Fig. 6a).
•A hand hold must be provided in the foundation block for the insertion of
the cotter (1).
•The bolt possesses a rectangular slot to receive the cotter. A cast-iron
washer (2) is also used as a bearing surface of the cotter.
Split end bolts
•The end of theses bolts are made splitted. The bent split facilitates a rigid
fixing of a bolt.
•Such bolts are mostly used for medium-size machine tools. (Figure 6b).
Figure 6: (a) Cotter
bolt; (b) Split end bolt.
25. c) Foundation Cont.
Major activities of foundation work
•The foundation involves the activities like digging-up the soil
(excavation), positioning of foundation bolts, concrete mixture
pouring and setting.
•Suppose the foundation plan of a ‘center lathe’ is supplied by the
manufacturer as shown in Figure (5.7) with proper dimensioning.
Figure 7:
Foundation plan of
a ‘center lathe’.
26. c) Foundation Cont.
• The erection work is undertaken mostly when the foundation
block has been set in and hardened.
• The machine tool is placed on the foundation with the help of
spacers or pads, leveling wedges, etc.
• Foundation plates are also supported similarly, for different
machines etc. At this time, a gap (minimum 50 to 70mm)
depending on the type of the machine is maintained between
the top of the foundation block and the bottom of the
machine or base plate.
• The foundation bolts are positioned before positioning the
machine and the exact location of the machine is guided by
the insertion of the projected foundation-bolt ends through
the holes, provided at the machine footings or base plate.
• The bolt-ends should remain sufficiently projected to
accommodate the washers and nuts as well.
27. d) Leveling and Alignment
• After having the machine on the foundation, the
important job is to level and align it with other
accessories.
• The leveling is performed with leveling wedges,
shoes etc. as stated before.
• The horizontal and slight vertical movements of the
heavy mass of machine is performed by pipes,
rollers as shown in Fig. 9a or using pinch bars (Fig.
9b).
• Straight edge, spiral level, dial indicator etc., are
generally useful instruments to level the machine.
• The leveling is to be checked in the both,
longitudinal and transverse direction.
29. d) Leveling Cont.
• The parallelity, perpendicularity of different faces, axes
should be leveled and aligned, as are required.
• When leveling is completed, the foundation bolt cavity
along with the bolt may be made concreted. Pouring of
cement concrete is generally made through the gap
provided at the top of the foundation, as shown in Fig.
10.
• This concreting will provide a bondage of the
foundation bolts with the foundation block while
performing grouting, discussed later.
• Whenever, the foundation block is continuously made
for a connected accessory, (say, the alternator with the
turbine) the relative alignment should be established
before concreting the foundation bolts.
31. d) Grouting
• Grouting is a procedure of connecting the machine with the
foundation by a concrete mixture of plastic consistency or
cement mortar. It is extensively used in installing most of the
machines.
• Generally, a quick setting cement is used to perform grouting.
The top of the foundation block is made roughned, made
moistened with water and wooden partitions are placed all-
around the machine.
• The heights of such wooden boards are kept much higher than
the gap between the top or the foundation and the bottom of the
machine.
• Quick setting cement is then poured within the boundary with
care to eliminate any air gap within it.
• Once started, the pouring should be completed continuously and
the machine must be felt undisturbed for a few days after
grouting to provide it time to set.
32. e) Fitting of other parts
• When the machine is erected, the other
accessories may be joined accordingly.
• But, while laying out the foundation plan, the
overall requirement should be kept in mind.
• The auxiliary structures e.g. in case of a heavy-
duty diesel engine foundation, the structures for
outer bearing pedestal, water pump blocks etc.
should be planned at a time.
• This will minimize the problem of internal
fittings.
33. f) Final leveling and test runs
• Accurate leveling can be carried out only when
the grouting has set in after a few days.
• The machine is to be made cleaned and leveled
then. Such leveling involves minor adjustments.
• Whenever provided, the leveling screws as shown
in Fig. 7. may be operated to achieve the final
level.
• Everything should now be made ready to carry the
test run. The style of testing will differ from
machine to machine.
• For instance, for metal-cutting machine tools, they
are always sent out with a test chart.
34. f) Final leveling Cont.
• ‘Test chart’ may be defined as the specification
of accuracies of major typical points like
‘straightness of guide ways’ ‘Trueness of
spindles’ etc. which should exist for the desired
functioning of the respective machines.
• The accuracy shown in the chart will be re-
obtained only if the machine is correctly erected
and leveled.